Search

Focusing on the problem of strip shape quality control in the finishing process of hot rolling, a shape model based on metal flow and stress release with the application of varying contact rolling parameters is introduced. Combined with digital twin technology, the digital twin framework of the shape model is proposed, which realizes the deep integration between physical time–space and virtual time–space. With the utilization of the historical data, the parameters are optimized iteratively to complete the digital twin of the shape model. According to the schedule, the raw material information is taken as the input to obtain the simulation of the strip shape, which shows a variety of export shape conditions. The prediction absolute error of the crown and flatness are less than 5 μm and 5 I-unit, respectively. The results prove that the proposed shape simulation model with strong prediction performance can be effectively applied to hot rolling production. In addition, the proposed model provides operators with a reference for the parameter settings for actual production and promotes the intelligent application of a shape control strategy. [ABSTRACT FROM AUTHOR]

Wheel burn can affect the wheel–rail contact state and ride quality. With long-term operation, it can cause rail head spalling or transverse cracking, which will lead to rail breakage. By analyzing the relevant literature on wheel burn, this paper reviews the characteristics, mechanism of formation, crack extension, and NDT methods of wheel burn. The results are as follows: Thermal-induced, plastic-deformation-induced, and thermomechanical-induced mechanisms have been proposed by researchers; among them, the thermomechanical-induced wheel burn mechanism is more probable and convincing. Initially, the wheel burns appear as an elliptical or strip-shaped white etching layer with or without deformation on the running surface of the rails. In the latter stages of development, this may cause cracks, spalling, etc. Magnetic Flux Leakage Testing, Magnetic Barkhausen Noise Testing, Eddy Current Testing, Acoustic Emission Testing, and Infrared Thermography Testing can identify the white etching layer, and surface and near-surface cracks. Automatic Visual Testing can detect the white etching layer, surface cracks, spalling, and indentation, but cannot detect the depth of rail defects. Axle Box Acceleration Measurement can be used to detect severe wheel burn with deformation. [ABSTRACT FROM AUTHOR]

Angular contact ball bearings are common basic components in rotating machinery. During the operation of the bearing, the rolling slips, resulting in contact sliding friction between it and the raceway, which in turn causes wear in the rolling element and increase in the radial clearance of the bearing. The increase in clearance also affects the stiffness of the bearing, which in turn affects the natural frequency and fatigue life of the bearing. At present, there are few studies on the influence of bearing wear (variation of clearance) on life. In this paper, the finite element model based on the theory of contact mechanics is established for the angular contact ball bearing with medium- and high-speed rotation, and the mechanical properties and fatigue life influenced by the internal action of the bearing are analyzed. The effects of radial load and deflection angle on the mechanical properties and fatigue life of the bearing are also studied. Based on the analysis results of bearing contact mechanical properties and clearance changes, the calculation method of bearing life under rolling element wear is established. The influence of the variation of clearance and preload clearance on bearing life is analyzed, and the optimal preload is obtained. The research results of this paper can provide a theoretical basis for optimizing the installation of angular contact ball bearings, reasonably determining the service conditions, and prolonging the service life of bearings, which is necessary for engineering practice. [ABSTRACT FROM AUTHOR]

Aiming at the problem of low control accuracy caused by nonlinear disturbances in the operation of the PLS-160 wheel–rail adhesion test rig, a linear active disturbance rejection controller (LADRC) suitable for the wheel–rail adhesion test rig was designed. The influence of nonlinear disturbances during the operation of the test rig on the control accuracy was analyzed based on SIMPACK. The SIMAT co-simulation platform was established to verify the control performance of the LADRC designed in this paper. The simulation results show that the speed and creepage errors of the test rig under the control of the LADRC met the adhesion test technical indicators under four different conditions. Compared with the traditional PID controller, the creepage overshoot and response time with the LADRC were reduced by 1.27% and 60%, respectively, under the constant creepage condition, and the stability recovery time was shorter under the condition of a sudden decrease in the adhesion coefficient. The LADRC designed in this paper shows better dynamic and anti-interference performance; therefore, it is more suitable for a follow-up study of the PLS-160 wheel–rail adhesion test rig. [ABSTRACT FROM AUTHOR]

Vision is the main component of current robotics systems that is used for manipulating objects. However, solely relying on vision for hand−object pose tracking faces challenges such as occlusions and objects moving out of view during robotic manipulation. In this work, we show that object kinematics can be inferred from local haptic feedback at the robot−object contact points, combined with robot kinematics information given an initial vision estimate of the object pose. A planar, dual-arm, teleoperated robotic setup was built to manipulate an object with hands shaped like circular discs. The robot hands were built with rubber cladding to allow for rolling contact without slipping. During stable grasping by the dual arm robot, under quasi-static conditions, the surface of the robot hand and object at the contact interface is defined by local geometric constraints. This allows one to define a relation between object orientation and robot hand orientation. With rolling contact, the displacement of the contact point on the object surface and the hand surface must be equal and opposite. This information, coupled with robot kinematics, allows one to compute the displacement of the object from its initial location. The mathematical formulation of the geometric constraints between robot hand and object is detailed. This is followed by the methodology in acquiring data from experiments to compute object kinematics. The sensors used in the experiments, along with calibration procedures, are presented before computing the object kinematics from recorded haptic feedback. Results comparing object kinematics obtained purely from vision and from haptics are presented to validate our method, along with the future ideas for perception via haptic manipulation. [ABSTRACT FROM AUTHOR]

When trains pass through damaged switch rails, rail head damage will change wheel–rail contact states from rolling frictions to unsteady contacts, which will result in impact vibrations and threaten structural safeties. In addition, under approaching and moving away rolling contact excitations and complex wheel–rail contacts, the non-stationary vibrations make it difficult to extract and analyze impact vibrations. In view of the above problems, this paper proposes a variational-mode-decomposition (VMD)-spectral-subtraction (SS)-based impact vibration extraction method. Firstly, the time domain feature analysis method is applied to calculate the time moments that the wheels pass joints, and to correct vehicle velocities. This can help estimate and confine impact vibration distribution ranges. Then, the stationary intrinsic mode function (IMF) components of the impact vibration are decomposed and analyzed with the VMD method. Finally, impact vibrations are further filtered with the SS method. For rail head damage with different dimensions, under different velocity experiments, the frequency and amplitude features of the impact vibrations are analyzed. Experimental results show that, in low-velocity scenarios, the proposed VMD–SS–based method can extract impact vibrations, the frequency features are mainly concentrated in 3500–5000 Hz, and the frequency and peak-to-peak features increase with the increase in excitation velocities. [ABSTRACT FROM AUTHOR]

Aiming at early detection of subsurface cracks induced by contact fatigue in rotating machinery, the knowledge-based data analysis algorithm is proposed for health condition monitoring through the analysis of acoustic emission (AE) time series. A robust fault detector is proposed, and its effectiveness was demonstrated for the long-term durability test of a roller made of case-hardened steel. The reliability of subsurface crack detection was proven using independent ultrasonic inspections carried out periodically during the test. Subsurface cracks as small as 0.5 mm were identified, and their steady growth was tracked by the proposed AE technique. Challenges and perspectives of the proposed methodology are unveiled and discussed. [ABSTRACT FROM AUTHOR]

This paper investigates the possibility of developing a new method for fault detection of a damper in the primary suspension of the railway vehicle, based on the analysis of the vertical vibration's response of the bogie. To this purpose, experimental data are used, along with results from numerical simulations regarding the Root Mean Square (RMS) accelerations measured/simulated in four reference bogie points—two points on the chassis, against the suspension, and two points located against the axle boxes. The experimental data are utilized to define the normal area of operating and the damper failure area in the bogie primary suspension, as well as a basis for validating the results of numerical simulations. The numerical simulations are developed on the basis of two original models of the vehicle–track system, rigid-flexible coupled type, which take into account the elasticity of the vehicle carbody and the elasticity of the wheel-rail contact: a reference model with 15 degrees of freedom, for simulating the bogie response to vertical vibrations for the normal operating of the primary suspension dampers, and an extended model with 20 degrees of freedom, for simulating the bogie vibration response to the failure damper of a primary suspension. The presented results show that there are clear premises on the possibilities of developing a fault detection method of any of the four dampers of the primary suspension corresponding to a vehicle bogie, based on the RMS accelerations measured only in two reference points of the bogie. [ABSTRACT FROM AUTHOR]

The operating condition of rolling bearings affects productivity and quality in the rotating machine process. Developing an effective rolling bearing condition monitoring approach is critical to accurately identify the operating condition. In this paper, a hybrid generalized hidden Markov model-based condition monitoring approach for rolling bearings is proposed, where interval valued features are used to efficiently recognize and classify machine states in the machine process. In the proposed method, vibration signals are decomposed into multiple modes with variational mode decomposition (VMD). Parameters of the VMD, in the form of generalized intervals, provide a concise representation for aleatory and epistemic uncertainty and improve the robustness of identification. The multi-scale permutation entropy method is applied to extract state features from the decomposed signals in different operating conditions. Traditional principal component analysis is adopted to reduce feature size and computational cost. With the extracted features' information, the generalized hidden Markov model, based on generalized interval probability, is used to recognize and classify the fault types and fault severity levels. Finally, the experiment results show that the proposed method is effective at recognizing and classifying the fault types and fault severity levels of rolling bearings. This monitoring method is also efficient enough to quantify the two uncertainty components. [ABSTRACT FROM AUTHOR]

The reliability of rolling element bearings has been substantially undermined by the presence of parasitic and stray currents. Electrical discharges can occur between the raceway and the rolling elements and it has been previously shown that these discharges at relatively high current density levels can result in fluting and corrugation damages. Recent publications have shown that for a bearing operating at specific mechanical conditions (load, temperature, speed, and slip), electrical discharges at low current densities (<1 mA/mm2) may substantially reduce bearing life due to the formation of white etching cracks (WECs) in bearing components, often in junction with lubricants. To date, limited studies have been conducted to understand the electrical discharges at relatively low current densities (<1 mA/mm2), partially due to the lack of robust techniques for in-situ quantification of discharges. This study, using voltage measurement and electrostatic sensors, investigates discharges in an oil-lubricated steel-steel rolling contact on a TE74 twin-roller machine under a wide range of electrical and mechanical conditions. The results show that the discharges events between the rollers are influenced by temperature, load, and speed due to changes in the lubricant film thickness and contact area, and the sensors are effective in detecting, characterizing and quantifying the discharges. Hence, these sensors can be effectively used to study the influence of discharges on WEC formation. [ABSTRACT FROM AUTHOR]

The following study presents an in situ sensor system which can measure the temperature change of rolling contacts for heavy duty during fluid as well as mixed friction. This thin-film sensor was optimized with regard to its size, spatial resolution, and wear resistance. Extensive tests were carried out with a two-disk test rig and the data of the temperature change were presented. The results show the complex processes within a rolling contact and the strongly interaction of pressure, friction, and temperature development within the contact zone. Due to the detailed sensor and disk characterization, the data are suitable for comparing calculation methods. [ABSTRACT FROM AUTHOR]

Tires are essential components of vehicles and are able to transmit traction and braking forces to the contact patch, contribute to directional stability, and also help to absorb shocks. If these components can provide information related to the tire–road interaction, vehicle safety can be increased. This research is focused on developing the tire as an active sensor capable to provide its functional parameters. Therefore, in this work, we studied strain-based measurements on the contact patch to develop an algorithm to compute the wheel velocity at the contact point, the effective rolling radius and the contact length on dynamic situations. These parameters directly influence the dynamics of wheel behavior which nowadays is not clearly defined. Herein, hypotheses have been assumed based on previous studies to develop the algorithm. The results expose to view an experimental test regarding influence of the tire operational condition (slip angle, vertical load, and rolling velocity) onto the computed parameters. This information is used to feed a fuzzy logic system capable of estimating the effective radius and contact length. Furthermore, a verification process has been carried out using CarSim simulation software to get the inputs for the fuzzy logic system at complex maneuvers. [ABSTRACT FROM AUTHOR]

The maintenance of railway systems is critical for their safe operation. However some landscape geographical features force the track line to have sharp curves with small radii. Sharp curves are known to be the main source of wheel flange wear. The reduction of wheel flange thickness to an extreme level increases the probability of train accidents. To avoid the unsafe operation of a rail vehicle, it is important to stay continuously up to date on the status of the wheel flange thickness dimensions by using precise and accurate measurement tools. The wheel wear measurement tools that are based on laser and vision technology are quite expensive to implement in railway lines of developing countries. Alternatively significant measurement errors can result from using imprecise measurement tools such as the hand tools, which are currently utilized by the railway companies such as Addis Ababa Light Rail Transit Service (AALRTS). Thus, the objective of this research is to propose and test a new measurement tool that uses an inductive displacement sensor. The proposed system works in both static and dynamic state of the railway vehicle and it is able to save the historical records of the wheel flange thickness for further analysis. The measurement system is fixed on the bogie frame. The fixture was designed using dimensions of the bogie and wheelset structure of the trains currently used by AALRTS. Laboratory experiments and computer simulations for of the electronic system were carried out to assess the feasibility of the data acquisition and analysis method. The noises and unwanted signals due to the dynamics of the system are filtered out from the sensor readings. The results show that the implementation of the proposed measurement system can accurately measure the wheel flange wear. Also, the faulty track section can be identified using the system recorded data and the operational control center data. [ABSTRACT FROM AUTHOR]

Modern railway track health monitoring requires high accuracy measurements to ensure comfort and safety. Although Global Navigation Satellite System/Inertial Navigation System (GNSS/INS) integration has been extended to track geometry measurements to improve the work efficiency, it has been questioned due to its positioning accuracy at the centimeter or millimeter level. We propose the relative spatial accuracy based on the accuracy requirement of track health monitoring. A requirement assessment of the spatial relative accuracy is conducted for shortwave track irregularity measurements based on evaluation indicators and relative accuracy calculations. The threshold values of the relative spatial accuracy that satisfy the constraints of shortwave track irregularity measurements are derived. Motion-constrained GNSS/INS integration is performed to improve the navigation accuracy considering the dynamic characteristics of the track geometry measurement trolley. The results of field tests show that the mean square error and the Allan deviation of the relative position errors of motion-constrained GNSS/INS integration are smaller than 0.67 mm and 0.16 mm, respectively, which indicates that this approach meets the accuracy requirements of shortwave track irregularities, especially vertical irregularities. This work can provide support for the application of GNSS/INS systems in track irregularity measurement. [ABSTRACT FROM AUTHOR]

Process force determination in machine tools is an important topic for both optimization of manufacturing processes as well as predictive maintenance purposes. This work aims at providing a short overview of existing methods, motivating the integration of sensors into a linear guide, and then showing the results of an implemented new method for capturing the load on a rolling element linear guide by measuring the stresses resulting from the rolling element contact at the side of the runner block. The implementation of the approach is based on the piezoresistive diamond like carbon (DLC) coating DiaForce® provided by the Fraunhofer Institute for Surface Engineering and Thin Films (IST), Braunschweig, Germany. Good agreement of measurements with analytical and finite element method simulation results promises a stable modeling and load estimation process. Nevertheless, non-idealities due to high temperature dependency and cross-sensitivity to non rolling element contact related stresses could be shown, but also an efficient approach to diminish these effects is included. [ABSTRACT FROM AUTHOR]

The rolling element bearing is a significant component in rotating machinery. Suitable bearing fault detection and diagnosis (FDD) is vital to maintaining machine operations in a safe and healthy state. To address this issue, an extended observer-based FDD method is proposed, which uses a variable structure feedback linearization observer (FLO). The traditional feedback linearization observer is stable; however, this technique suffers from a lack of robustness. The proposed variable structure technique was used to improve the robustness of the fault estimation while reducing the uncertainties in the feedback linearization observer. The effectiveness of the proposed FLO procedure for the identification of outer, inner, and ball faults was tested using the Case Western University vibration dataset. The proposed model outperformed the variable structure observer (VSO), traditional feedback linearization observer (TFLO), and proportional-integral observer (PIO) by achieving average performance improvements of 5.5%, 8.5%, and 18.5%, respectively. [ABSTRACT FROM AUTHOR]